Micro-embossing of micro-structures in RSA-501 as mold inserts for the replication of micro-lens arrays

• DOI: 10.1016/j.rineng.2022.100793
• Publication Date: 2022-12-01T20:00:25Z
• Authors: Julian Kober; Daniel Rolón; Florian Hölzel; Stefan Kühne; Dirk Oberschmidt; Thomas Arnold
• Keywords: Embossing; Microlens; Replication

The production of mold inserts for the replication micro-lens arrays through micro-embossing could be an alternative process route compared to diamond turning or milling in order reduce time and costs. rapidly solidified aluminum alloy RSA-501 is expected form micro-structures with low surface roughness because its ultra-fine grain structure. In challenges like elastic spring back effect, pile-ups, forming accuracy depend on material behavior. Therefore, was further characterized influence polishing flycutting behavior investigated. To understand microstructure samples were sectioned along their cross longitudinal directions. structure oriented extrusion direction mean sizes <1.00 μm. Furthermore, micro-embossed investigate preparation micro-structures. induced integrity not deep enough workpiece can prepared either by flycutting. When RSA-501, sections used. However, it recommended section isotropic It shown that curvature radius concave structures differs from tool radius. This due effect. Since embossed remains spherical, effect compensated adjusting